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Forums › Tuning, Modification & Legal › Project Cars › Project KKN Sport |
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 Posted: Mon Apr 16, 2018 9:29 am |
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Joined: Apr 12, 2018
Posts: 24
Trade Rating: 0
Location: Kent
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New here! Probably one of the only females on the site so i’ll Introduce myself.
I’m 21, and have a 1.4 16V Sport project, (ET3J4) in KKN red, 2005, 5 door.
So when I got it, it was a bit of a mess and I’ve thrown silly amounts of money at it, replacing the whole front end due to a variety of marks and dents all over be bumper and wing, also put some flared wings on her! Replaced the clutch & clutch cable immediately before driving, Cambelt, center pipe from the exhaust, pads, rear boot trim (lacquer was non existent), full service and replaced with Bosch parts, and some NKG spark plugs, brembo discs and pads, (yet to fit discs, thanks to euros for sending me the wrong ones!).
My mod list is also quite extensive and so is my ‘to fit, to do’ list and my ‘future ideas’ list.
So I will start with the obvious...
16” Nimrods (sprayed black & glittery, my girly touch! With red center caps.
95% tint on all 3 rear windows.
Gel plates.
Blacked foglight
(Lexus lights no longer on, LED’s in the making.)
GTI alloy fuel cap
Now lowered 50mm
2010 Peugeot logo (matte black) on the rear.
Front badge black.
Full SP grills.
Spoiler
Red center console, vent surround and handle surrounds.
Red dial surrounds
Red gear gaitor
red A-pillars
6x9 parcel shelf speakers
Wind deflectors
Front fog lights yellow tinted
Chrome vent sliders
Chrome handbreak button
Red felt ashtray
Angel eye headlights, with LED dipped beam, osram full beam
Gti180 carbon wingmirror caps
Gloss black mirrors from GTIHDI
Mk4 Astra splitter
Red calipers
Red dust caps
Sport3 interior
GTI steering wheel
I also have a set of Sp arches that I’m hunting down clips for, one single clip at a time.
The angel eyes are coming off soon to be customised and totally rebuilt and rewired. Led rear lights have also been dismantled to be sprayed and fixed.
Mud flaps to fit, and a ton of other stuff.
I also have a DV41.4 HDI converted to a DV6 1.6 GTIHDI  in the making still!
I have a few questions that I’d like a little help with!
During the angels rebuild I will be replacing the rings with led rings, does anyone know the measurement for the rings?
Rear arch, mine is dented, quite extensively, is this a cut n weld job?
UPDATES: 26-06-2018
So FCS18 is coming up so I’ve been a bit quiet between prettying two cars.
Angel eye rebuild is underway, I will update on that in a few weeks!
So far...
-GTI leather clock surround
-GTI steering wheel
-replaced broken passenger wing mirror
-sunstrip
-carbon door handle surrounds & chrome handle
-SP Bonnet Vent
-backbox delete
-silicone hosing in the engine bay
And got awaiting fitting:
-polybushed wishbones
-polybushed lowered GTI180 axle
-top mount bearing
-new alternator
-Vortex Alloys
Have also got these as temporary headlights at the moment, and I’m completely in love with them!
I have also finally got the bonnet replaced after an 18 month hunt for a KKN bonnet, and have also now got an Astra MK4 splitter fitted!
!!!UPDATE 10/09/18!!!
1. Angel eye rebuild is very close to being completed, after several months of graft, glue, cleaning, dismantling, getting spare parts and such. Will post updates to that soon.
2. 1.4 16V to 1.6 16V will be happening soon, again, updates coming soon, still got a few more bits to get
So the angel eye rebuild has taken a slight turn for the worst. They were originally stuck together with windscreen bond. Turns out windscreen bond disolves sillicone and pinkgrip. The sport has also encountered an unexpected coil pack problem. Much to my annoyance. (Update 24/10/18, not got much further!)
(Update 24/10/18)
Sh*t hit the fan. Two weeks ago, a few days after my little coil pack hiccup, my thermostat got stuck, blew my head gasket and warped my head. (Generally what happens when the car is stuck at 130 degrees for 10 minutes).
Project 1.6 16V... well underway.
Thanks dad for picking the engine up for me.
Thanks Ben for getting the TU5 in the back of his KA Sport for me (possible, definitely slammed!).
Thanks Liam, my dedicated fiancé who’s helped me and worked his butt off, taking turns looking after our daughter while we go out and crack on with the car, my world.
Thanks mum for being my on-call emergency babysitter once again!
THURSDAY
At 6pm the bonnet opened, bumper, grill, fan and rad off, airbox out, pipes dismantled, oil drained, coolant drained, battery and tray out, aux belt off, a lot of labelling wires. By 9pm she looks a little like this...
FRIDAY
Little progress, cambelt off, camshafts out, pulleys out, for the sake of it rather than progress.
SATURDAY
10am, picked engine up. (Thankyou again Ben for getting it into your KA!)
11am, picked up more gloves.
12pm, back home.
3pm, the 1.4 was out.
The 2006 1.6 16V has a hydrolic gearbox, all the 16V’s have the same clutch, we had two near new clutches for it.
The 1.6+ engines have a different upper right engine mount, (left as you look at the bay, under fuse box.)
You can fit a non-hydrolic gearbox in place of a hydrolic gearbox, which is exactly what we did, we couldn’t figure the hydrolic box out.
Following all this, I degreased the engine down totally, making it near on new-looking, fitted a red engine cover and bolts, dusted off the cobwebs, encountered a spider or two.
Engine, immaculate.
10pm, pack up, time to sleep.
SUNDAY
This is where we encountered problems. Bear with, this isn’t my strong point but will do my best to explain.
The 1.4 ECU- 3 connectors, one small from the BSI/fusebox. One small one big from the engine loom.
The 1.6 engine loom only had 2 small connectors, obviously paired with the small connector from my bsi, we have a problem. A big hole in the ecu and not enough wires.
Things halted a little. Needed to get to the bottom of the ecu/loom and needed an engine mount.
First port of call, eBay for an ecu/bsi set. Couldn’t find any with 3 small holes. Gut feeling we’re missing something.
Sleep on it.
MONDAY
Scrap yard trip. Left with an engine mount. Fitted it when we got back.
Then we laid out the engine looms and sat on the floor staring at them for a good hour, muttering to ourselves and thinking out loud while drinking coffee.
Newest theory... the large plug comes from the bsi on the 1.6... but how far does that wiring go?
Also trial fitted a set of canards on my bumper.
TUESDAY
4 hours removing a loom at a scrap yard, we finally have everything we need...
WEDNESDAY
Took a day off, stressed
THURSDAY
Loom fitted, started putting everything back together, battery tray back on, last few nuts and bolts in the rad/lights.
SATURDAY
Plugging in the ecu, bsi, touched pos on battery, alternator sparked, unplugged alternator, connected battery, safe start... turned and didn’t fire
Upon investigating, there’s no fuel or spark. Must have double triple octuple times checked it wasn’t the immobiliser, still nothing. I will write this out clearer so if anyone else has the same problem they can relate.
No fuel, no spark, acting like an immobiliser fault, but not an immobiliser fault. Fuel pump not priming but primes if hardwired, still no spark. No power to coil pack.
We trialled and error a lot of things, starter motor, pulled out half of the wiring to see if there was broken cables, nothing.
Fan also on constantly (still unresolved, fixed itself)
Cause of the problem: the ecu and engine loom had an alarm. I didn’t have an interior loom with an alarm, this acts as a second immobiliser and shuts off fuel and spark as the car thinks it’s being stolen.
Now need to find a 1.6 16V interior loom with an alarm.
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Last edited by Projectsport on Mon Nov 19, 2018 8:16 am; edited 7 times in total
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Posted: Tue Apr 17, 2018 10:01 pm |
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Joined: Jan 12, 2018
Posts: 68
Trade Rating: 0
Location: Warsaw - Poland
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Very nice! Welcome to the forum!
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Posted: Wed Apr 18, 2018 4:31 pm |
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Joined: Sep 14, 2012
Posts: 391
Trade Rating: 0
Location: Middlesbrough
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Welcome to the forum! Looking good and plans sound interesting, keep us all updated 
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Posted: Tue May 01, 2018 11:17 am |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Proper well looked after 5-door family friendly hot hatch! Welcome 
Particularly interested in your Angel Eyes LED rings conversion, keep us posted!
PS: how about spraying SP grilles in black for a brave experiment?
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Posted: Thu May 03, 2018 7:50 pm |
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Joined: Oct 09, 2017
Posts: 60
Trade Rating: 0
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Looking good! I drive a 5 door myself! Have you done the USDM mod on your indicators?
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Posted: Wed Jun 27, 2018 6:24 pm |
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Joined: Apr 12, 2018
Posts: 24
Trade Rating: 0
Location: Kent
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Posted: Sat Sep 15, 2018 12:57 pm |
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Joined: Apr 12, 2018
Posts: 24
Trade Rating: 0
Location: Kent
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| Sim wrote: |
Proper well looked after 5-door family friendly hot hatch! Welcome
Particularly interested in your Angel Eyes LED rings conversion, keep us posted!
PS: how about spraying SP grilles in black for a brave experiment? |
I’m looking into some genuine zunsport black SP grills actually ☺️
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Posted: Fri Oct 26, 2018 4:12 pm |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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| Projectsport wrote: |
| I’m looking into some genuine zunsport black SP grills actually ☺️ |
Those are smart indeed!
Gotta really like those new DRLs you've got. Reminds of the evil/devil horns/eyes back in a day, but much sleeker as it's a smooth LED strip.. at least it looks like that on the photo, that even Audi R8 would envy for
Sad to hear about the blown-up 1.4, but congrats to your perseverance -- now you'll get an upgrade to 1.6 and get to keep all the work that has gone into the car so far!
PS: I've only now noticed that you've been updating your first post. If you could bump the thread by replying to it, we would then get the notifications.
Regarding the dented rear arch: yes, usually it's cut'n'weld job if otherwise too big to pull out and fill.
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Posted: Mon Nov 19, 2018 8:04 am |
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Joined: Apr 12, 2018
Posts: 24
Trade Rating: 0
Location: Kent
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I’ll finish the bit I’m on then do updates in the comments for the sake of notifications
The LED’s definitely attract attention, they are a solid strip, intact I recently finished my side project of doing the same to a set of angel eyes, which I will add photos of when they run!
It’s definitely been an experience, learnt a lot about the car, about French wiring, and some useful tips for the future... first things first... if your swapping an engine, get an entire donor car, don’t try do it with bits of a car!
Hmm. Potentially cut and weld then, it’s pretty big and dented in, only dent left on the car now!
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Posted: Fri Jan 18, 2019 11:22 pm |
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Joined: Apr 12, 2018
Posts: 24
Trade Rating: 0
Location: Kent
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UPDATE
so, secretly got her running back in december, kept quiet as i wanted her 'back on all 4's before i announced it. since then, have been faffing with the exhaust a lot, getting sensors, housing, and ordering parts to ensure it's 100% MOT passable. tracking arranged, dyno arranged, MOT arranged.
tomorrow bits such as the goodridgr braided hoses will be fitted and maybe wn oil breather solution!
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Posted: Sat Jan 19, 2019 2:51 pm |
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Joined: Dec 26, 2013
Posts: 326
Trade Rating: +1
Location: East London
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Love the angel eyes! Will be keeping an eye out for this thread for sure
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| Current: Albi Blue Clio 197
Previous: EZR 1.1 206 Zest 3 5dr | |
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Posted: Sun Feb 03, 2019 7:39 pm |
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Joined: Apr 12, 2018
Posts: 24
Trade Rating: 0
Location: Kent
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next update
she's all mechanically back together, runs sweet as, sounds the nuts. currently working through a list of warning lights and clearing 1 by 1 so she will pass an mot, hopefully the next week or so!
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Posted: Fri Feb 22, 2019 3:40 pm |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Congrats! Perseverance wins again
Was the 1.6 16v ECU super sensitive to transplants and kept frying itself hence not sending a spark? I bet we're all interested in the rootcause
Post up some dyno results!
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Posted: Fri Mar 01, 2019 6:41 am |
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Joined: Apr 12, 2018
Posts: 24
Trade Rating: 0
Location: Kent
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Posted: Wed May 29, 2019 10:57 pm |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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A nice 30% increase in power, well done!
Is it the intake+exhaust+remap that contributed to?
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